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XT250X
Yamaha XT250X Manuals
Manuals and User Guides for Yamaha XT250X. We have
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Yamaha XT250X manuals available for free PDF download: Service Manual, Owner's Manual
Yamaha XT250X Service Manual (282 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 8.52 MB
Table of Contents
Table of Contents
7
How to Use this Manual
5
Symbols
6
General Information
9
Identification
10
Vehicle Identification Number
10
Model Label
10
Important Information
11
Preparation for Removal and Disassembly
11
Replacement Parts
11
Gaskets, Oil Seals and O-Rings
11
Lock Washers/Plates and Cotter Pins
11
Bearings and Oil Seals
11
Circlips
12
Checking the Connections
13
Special Tools
14
Specifications
19
General Specifications
20
Engine Specifications
21
Chassis Specifications
28
Electrical Specifications
30
Tightening Torques
32
General Tightening Torque Specifications
32
Engine Tightening Torques
32
Chassis Tightening Torques
34
Lubrication Points and Lubricant Types
37
Engine
37
Chassis
38
Lubrication System Chart and Diagrams
40
Engine Oil Lubrication Chart
40
Lubrication Diagrams
42
Cable Routing
44
Periodic Checks and Adjustments
55
Periodic Maintenance
56
Introduction
56
Periodic Maintenance Chart for the Emission Control System
56
General Maintenance and Lubrication Chart
57
Adjusting the Valve Clearance
60
Adjusting the Engine Idling Speed
61
Adjusting the Throttle Cable Free Play
62
Checking the Spark Plug
63
Checking the Ignition Timing
63
Measuring the Compression Pressure
64
Checking the Engine Oil Level
65
Changing the Engine Oil
66
Adjusting the Clutch Cable Free Play
67
Replacing the Air Filter Element
68
Checking the Carburetor Joint and Intake Manifold
69
Checking the Fuel Line
69
Checking the Cylinder Head Breather Hose
69
Checking the Exhaust System
69
Engine
60
Chassis
71
Adjusting the Front Disc Brake
71
Adjusting the Rear Disc Brake
71
Checking the Brake Fluid Level
72
Checking the Front Brake Pads
72
Checking the Rear Brake Pads
73
Checking the Front Brake Hose
73
Checking the Rear Brake Hose
73
Adjusting the Rear Brake Light Switch
73
Bleeding the Hydraulic Brake System
74
Adjusting the Drive Chain Slack
75
Lubricating the Drive Chain
75
Checking and Adjusting the Steering Head
76
Checking the Front Fork
77
Adjusting the Rear Shock Absorber Assembly
77
Checking the Tires
78
Checking the Wheels
79
Checking and Tightening the Spokes
80
Checking and Lubricating the Cables
80
Lubricating the Levers
80
Lubricating the Pedal
80
Lubricating the Sidestand
80
Lubricating the Rear Suspension
80
Electrical System
81
Checking and Charging the Battery
81
Checking the Fuses
81
Replacing the Headlight Bulb
81
Adjusting the Headlight Beam
81
Chassis
83
General Chassis
85
Front Wheel
86
Removing the Front Wheel
88
Checking the Front Wheel
88
Disassembling the Front Wheel
88
Assembling the Front Wheel
89
Adjusting the Front Wheel Static Balance
89
Installing the Front Wheel (Disc)
90
Rear Wheel
92
Removing the Rear Wheel (Disc)
94
Disassembling the Rear Wheel
94
Checking the Rear Wheel
94
Checking and Replacing the Rear Wheel Sprocket
94
Assembling the Rear Wheel
95
Adjusting the Rear Wheel Static Balance
95
Installing the Rear Wheel
95
Front Brake
96
Introduction
101
Checking the Front Brake Disc
101
Replacing the Front Brake Pads
102
Removing the Front Brake Caliper
103
Disassembling the Front Brake Caliper
103
Checking the Front Brake Caliper
103
Assembling the Front Brake Caliper
104
Installing the Front Brake Caliper
104
Removing the Front Brake Master Cylinder
105
Checking the Front Brake Master Cylinder
105
Assembling the Front Brake Master Cylinder
106
Installing the Front Brake Master Cylinder
106
Rear Brake
108
Introduction
113
Checking the Rear Brake Disc
113
Replacing the Rear Brake Pads
113
Removing the Rear Brake Caliper
114
Disassembling the Rear Brake Caliper
114
Checking the Rear Brake Caliper
115
Assembling the Rear Brake Caliper
115
Installing the Rear Brake Caliper
115
Removing the Rear Brake Master Cylinder
116
Checking the Rear Brake Master Cylinder
117
Assembling the Rear Brake Master Cylinder
117
Installing the Rear Brake Master Cylinder
117
Handlebar
119
Removing the Handlebars
120
Checking the Handlebar
120
Installing the Handlebar
120
Front Fork
123
Removing the Front Fork Legs
126
Disassembling the Front Fork Legs
126
Checking the Front Fork Legs
127
Assembling the Front Fork Legs
127
Installing the Front Fork Legs
130
Steering Head
131
Removing the Lower Bracket
133
Checking the Steering Head
133
Installing the Steering Head
133
Rear Shock Absorber Assembly
135
Handling the Rear Shock Absorber
136
Disposing of a Rear Shock Absorber
136
Removing the Rear Shock Absorber Assembly
136
Checking the Rear Shock Absorber Assembly
136
Checking the Connecting Arm and Relay Arm
136
Installing the Relay Arm
136
Installing the Rear Shock Absorber Assembly
137
Swingarm
138
Removing the Swingarm
139
Checking the Swingarm
139
Installing the Swingarm
139
Chain Drive
141
Removing the Drive Chain
142
Checking the Drive Chain
142
Checking the Drive Sprocket
143
Installing the Drive Chain
143
Engine
145
Engine Removal
147
Installing the Engine
150
Installing the Shift Pedal
150
Cylinder Head
152
Removing the Cylinder Head
154
Checking the Cylinder Head
155
Checking the Tappet Covers and Camshaft Sprocket Cover
155
Checking the Camshaft Sprocket and Timing Chain Guide (Exhaust System Side)
155
Checking the Timing Chain Tensioner
156
Installing the Cylinder Head
156
Camshaft
159
Removing the Rocker Arms and Camshaft
160
Checking the Camshaft
160
Checking the Rocker Arms and Rocker Arm Shafts
161
Installing the Camshaft and Rocker Arms
161
Valves and Valve Springs
164
Removing the Valves
164
Checking the Valves and Valve Guides
164
Checking the Valve Seats
166
Checking the Valve Springs
167
Installing the Valves
169
Cylinder and Piston
171
Removing the Piston
172
Checking the Cylinder and Piston
172
Checking the Piston Rings
173
Checking the Piston Pin
174
Installing the Piston and Cylinder
174
Clutch
176
Removing the Clutch
179
Checking the Friction Plates
179
Checking the Clutch Plates
179
Checking the Clutch Springs
179
Checking the Clutch Housing
180
Checking the Clutch Boss
180
Checking the Pressure Plate
180
Checking the Clutch Push Rods
180
Checking the Primary Drive Gear
180
Checking the Primary Driven Gear
180
Installing the Clutch
180
Oil Pump and Balancer Gear
184
Removing the Balancer Gear
186
Checking the Oil Pump
186
Checking the Oil Strainer
186
Assembling the Oil Pump
187
Install the Oil Pump and Balancer Gear
187
Shift Shaft
189
Checking the Shift Shaft
190
Checking the Stopper Lever
190
Installing the Shift Shaft
190
Generator and Starter Clutch
191
Removing the Generator
193
Removing the Starter Clutch
193
Checking the Starter Clutch
193
Installing the Starter Clutch
194
Installing the Generator
194
Electric Starter
196
Checking the Starter Motor
198
Assembling the Starter Motor
199
Crankcase
200
Disassembling the Crankcase
202
Checking the Crankcase
202
Checking the Timing Chain, Crankshaft Sprocket, Timing Chain Guide (Intake Side)
202
Checking the Bearing and Oil Seal
202
Assembling the Crankcase
202
Crankshaft Assembly
205
Removing the Crankshaft Assembly
205
Checking the Crankshaft and Connecting Rod
205
Installing the Crankshaft Assembly
205
Transmission
207
Checking the Shift Forks
209
Checking the Shift Drum Assembly
209
Checking the Transmission
209
Installing the Shift Forks and Shift Drum Assembly
210
Fuel System
211
Fuel Tank
213
Checking the Fuel Cock
213
Carburetor
214
Checking the Carburetor
217
Assembling the Carburetor
218
Installing the Carburetor
219
Air Induction System
220
Checking the Air Induction System
223
Electrical System
225
Ignition System
226
Circuit Diagram
226
Troubleshooting
228
Electric Starting System
230
Circuit Diagram
230
Starting Circuit Cut-Off System Operation
232
Troubleshooting
234
Charging System
236
Circuit Diagram
236
Troubleshooting
238
Lighting System
240
Circuit Diagram
240
Troubleshooting
242
Signaling System
244
Circuit Diagram
244
Troubleshooting
246
Carburetor Heating System
250
Circuit Diagram
250
Troubleshooting
252
Electrical Components
254
Checking the Switches
258
Checking the Bulbs and Bulb Sockets
261
Checking the Fuse
262
Checking and Charging the Battery
262
Checking the Relays
265
Checking the Turn Signal Relay
266
Checking the Diode
267
Checking the Spark Plug Cap
267
Checking the Ignition Coil
268
Checking the Pickup Coil
269
Checking the Stator Coil
269
Checking the Rectifier/Regulator
270
Checking the Horn
270
Checking the Speed Sensor
271
Checking the Thermo Switch
271
Checking the Carburetor Warmer
272
Troubleshooting
273
General Information
274
Incorrect Engine Idling Speed
274
Starting Failures
274
Faulty Clutch
275
Faulty Gear Shifting
275
Jumps out of Gear
275
Poor Medium-And-High-Speed Performance
275
Shift Pedal Does Not Move
275
Faulty Front Fork Legs
276
Faulty Lighting or Signaling System
276
Overheating
276
Poor Braking Performance
276
Unstable Handling
276
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Yamaha XT250X Owner's Manual (100 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 2.15 MB
Table of Contents
Important Manual Information
4
Table of Contents
6
Safety Information
8
Location of Important Labels
12
Description
16
Left View
16
Right View
17
Controls and Instruments
18
Instrument and Control Functions
19
Main Switch/Steering Lock
19
Indicator Lights
20
Multi-Function Display
21
Clock Mode
21
Handlebar Switches
22
Clutch Lever
23
Shift Pedal
23
Brake Lever
24
Brake Pedal
24
Fuel Tank Cap
24
Fuel
25
Fuel Cock
26
Starter (Choke) Knob "1
27
Seat
27
Helmet Holder
28
Adjusting the Shock Absorber
28
Assembly
28
Sidestand
30
Ignition Circuit Cut-Off System
30
Pre-Operation Checks
32
Pre-Operation Check List
33
Operation and Important Riding Points
35
Starting and Warming up a Cold Engine
35
Starting a Warm Engine
36
Shifting
36
Engine Break-In
38
Parking
38
Periodic Maintenance and Minor Repair
39
Periodic Maintenance
39
Owner's Tool Kit
39
Periodic Maintenance Chart for the Emission Control System
41
General Maintenance and Lubrication Chart
43
Removing and Installing the Cowling and Panels
47
Checking the Spark Plug
49
To Check/Install Spark Plug
50
To Change Engine Oil
51
Canister (for California Only)
51
Engine Oil and Oil Filter Element
51
Replacing the Air Filter Element and Cleaning the Check Hose
54
Cleaning the Spark Arrester
55
Checking the Engine Idling
56
Carburetor
56
Speed
56
Checking the Throttle Cable Free Play
57
Valve Clearance
57
Tires
57
Spoke Wheels
59
Accessories and Replacement Parts
60
Adjusting the Clutch Lever Free Play
60
Adjusting the Brake Lever Free Play
61
Adjusting the Rear Brake Light Switch
62
Checking the Front and Rear Brake Pads
62
Checking the Brake Fluid Level
63
Changing the Brake Fluid
64
Drive Chain Slack
64
Cleaning and Lubricating the Drive Chain
65
Checking and Lubricating the Cables
66
Checking and Lubricating the Throttle Grip and Cable
66
Checking and Lubricating the Brake and Shift Pedals
66
Checking and Lubricating the Brake and Clutch Levers
67
Checking and Lubricating the Sidestand
68
Lubricating the Rear Suspension
68
Checking the Front Fork
68
Checking the Steering
69
Checking the Wheel Bearings
70
Battery
70
Replacing the Fuse
71
Replacing the Headlight Bulb
72
Replacing the Tail/Brake Light Bulb
73
Replacing a Turn Signal Light Bulb
74
Supporting the Motorcycle
75
Front Wheel
75
Rear Wheel
76
To Install Front Wheel
76
Troubleshooting
78
Troubleshooting Chart
79
Motorcycle Care and Storage
80
Matte Color Caution
80
Care
80
Storage
82
Specifications
84
Consumer Information
87
Identification Numbers
87
Reporting Safety Defects
89
Motorcycle Noise Regulation
90
Maintenance Record
91
Yamaha Motor Corporation, U.s.a. Street and Enduro Motorcycle Limited Warranty
93
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